This paper presents the design and experimental validation of a synchronous reluctance motor (SynRM) using multilayer (ML) AC winding that meets the ultra-premium/ IE5 class efficiency requirement. Compared to conventional double layer AC windings, the ML winding yields a more sinusoidal stator MMF with shorter end-turn length. The ML winding is characterized using analytical stator MMF model with verification against finite element analysis (FEA). The proposed winding configuration is optimized under a given design benchmark. The multi-barrier rotor design is also optimized based on FEA using genetic algorithm (GA). Performance of the designed ML-SynRM is compared against a commercial premium efficiency induction motor and a conventionally wound SynRM for the same standard frame and cooling type. Results shows significant efficiency gain with SynRM designs, and also, the designed ML-SynRM yields lower torque ripple with improved power factor compared to conventional SynRM. Prototype ML-SynRM is built and its simulation results are experimentally validated against the benchmark including their performances at thermal steady-state.